THE BLUE SERIES

What is the Blue Series doing?

The Blue Series is a set of different camera systems for measurements and scanning of objects attached
to an industrial robot or a cobot. The camera delivers measurement data for the observed objects. Some
models are suitable for guiding of the robot in real-time including during welding. Some are suitable for
inspection.

Knowing When Welding Sensors Make Sense

Topics: Arc Welding, Tips and Tools
Since the revolutionary launch of welding robots over 40 years ago, innovation and process
improvements have continued to permeate product development focused on customer needs. In
the past, it was easy to program a robot to turn an arc on and weld a simple yet short seam with
many different types of metal joints. However, not all components are created equal.
Over time, the need arose for smarter machines capable of delivering greater efficiency, fewer
errors, less rework and lower cycle times. As a result, weld processes and robots have greatly
improved, and manufacturing industries are deploying industrial robots at an exponential rate to
reduce operational costs and increase profit margins.
The competitive nature of the industrial landscape continues to demand advancements in
technology. For welding, this newfound intelligence is most commonly achieved through a
variety of sensor technologies that have taken welding automation to a new height.
Different Types of Sensors
Sensors, like robots, come in a variety of shapes, sizes and prices. Similarly, sensors do no
good on their own and require intuitive software to function. When a sensor is linked with good
software and a robot is combined with good programming, automation is achievable. The
following insight will help robot users explore a variety of sensors to gain an understanding of
what may be feasible with their new or existing welding workcell.
Sensors that are used specifically for welding robot applications, typically fall into four
categories: touch, through-arc, laser and vision. Likewise, they have three primary functions:
seam finding, seam tracking, and/or part scanning, which can also be used for inspection.
Each function has unique advantages depending on part and ultimately the end goal, which
often relies heavily on the budget established. Most of these technologies can be mixed and
matched, where use is not redundant, and the understanding of these sensor technologies – in
order of cost and complexity (starting with low-cost, simple solutions) – is often helpful for robot
users looking to improve operations.
Through-Wire Touch Sense
Touch sense, sometimes referred to as “wire touch”, is the physical touch of a weld wire from
the end of the torch to detect the conductive surface of a part about to be welded. The system
uses a low voltage circuit during a low speed search to detect the weld joint. Although there is
no hardware mounted on the robot, a wire cutter and wire brake for consistent and accurate
sensing is required.
Touch sense can be completed through built-in features on a welding power supply designed for
automation, but it has been proven to have the best speed and accuracy with a separate
dedicated circuit, like the Yaskawa branded Touch Sense package. This process is slower than
laser technologies as one must wait for the robot to physically move to the detection location,
and then slowly approach the spot for best accuracy (up to 120 inches per minute).
BEST FOR: Finding orientation of parts with simple joints and geometries
NOT RECOMMENDED FOR: Thin materials less than 3/16” with small joint thickness; Square
butt joints; High-demand cycle times
COMPLEXITY: Low; Built-in pendant commands
COST: Low

Through-Arc Seam Tracking

Innovative technology, like Yaskawa’s ComArcthrough-the-arc seam tracker, uses a solid-state
sensor mounted near the welding power supply to actively measure arc characteristics during a
weld to determine variations between the robot’s taught path and the actual seam path. The
function applies minor corrections to amend the programmed path to follow the physical seam
during welding. Welding speed is regulated to a moderate 50 inches per minute. Return on
investment (ROI) with this technology is generally much lower than modifying and reengineering
parts and fixture tooling in such a way that it eliminates all potential seam variation.
BEST FOR: Parts with long or curved seams with some variation from part to part
NOT RECOMMEND FOR: Thin material less than 3 mm or non-weaving weldments; Large
gaps; Weldments less than 6” or requiring greater than 50 inches per minute travel speed.
COMPLEXITY: Low; Prewritten programs and algorithms provide smooth and easy operation
COST: Low

Laser Sensing
The most basic use of a laser sensor is a non-contact, 2-5x faster option to “touch sensing,” as
most of the robot motion required is eliminated to acquire the part location. Instead of a
physical, wire touch to a part, a laser dot and sensor captures the location and orientation of a
part as quickly as the laser fires. While it is still easy to teach, it requires a torch-mounted
sensor. And, like touch sense, it cannot find square butt joints and can potentially run into issues
with highly reflective surfaces. However, it eliminates the need for a wire cutter and wire break,
and it can detect lap joints down to 1/16” thick.
This system also requires a torch-mounted laser that could limit torch access in some tight
areas on the weldment. Yaskawa’s AccuFast™ laser sensing solution also works with any
welding power supply. A company’s investment when upgrading to this technology would
equate to about $20 per work day over a year, but an allowance for an additional 26 cycles per
shift (based on a 90 second cycle time) should be made, when compared to touch sensing
technologies. High output facilities commonly realize return on investment in less than one
month.
BEST FOR: Faster cycle times without breaking the budget
NOT RECOMMEND FOR: Square butt joints; Larger or inconsistent gaps; Highly reflective cut
or polished materials; Weldments with limited joint access
COMPLEXITY: Low-Medium; Some basic user training required with built-in commands
COST: Medium
2D Camera
Camera systems, such as Cognex, allow a user to capture the location of a part in a mere
second with a camera sensor mounted to the arm of the robot. Not only does this system find
the location of the part, but also, it quickly confirms orientation without adding many extra test
points as required with touch or laser sensing.
Because the unit is grabbing a wider image, it can also be used to ID the fixture being used and
prevent called job errors. As a downside, it is more sensitive to lighting and surface conditions. It
also does not provide depth of field, so stacked parts can be more difficult to program. As a
bonus, this camera can even be used to verify Tool Center Point (TCP) for quick realignment.
Return on investment goes up a little in time due to the custom programming required, but
proper use will often enable automation that would have been previously impossible or more
expensive.
BEST FOR: Parts with higher variability on placement and very demanding cycle times
NOT RECOMMEND FOR: Applications with large variations in depth, lighting or material
surface conditions
COMPLEXITY: High; Additional user training required
COST: Medium-High

Laser Seam Tracking

When the latest technology laser sensors are combined with high-speed controllers, seam and
part locations can be processed in real time. Like through-arc solutions, a dedicated program
compensates path and even adapts welding parameters for seam location and variation.
Yaskawa MotoEye™ LT or Servo-Robot DIGI-I/Power-Cam products reliably track thin gauge
metals and allow simultaneous welding 2x faster than through-arc tracking at up to 100 inches
per minute. This allows automation in parts that inherently have changing gaps, such as welding
around larger cylinders. Like laser sensing hardware, this also requires a box that may limit the
torch access into tight areas of the weldment.
This sensor is also used for weld inspection when coupled with a proper data tracking system.
Weld inspection and traceability is quickly becoming an industry standard for automotive and
safety critical welds. Arc data from the power supply is combined with individual scans of the
weld to track each part that comes through production. Return on investment here comes as a
figurative insurance policy that can reduce wide spread part recalls and the weighty liability that
comes with any potential part failure.
BEST FOR: Thin materials with varying seams that demand the fastest potential cycle time
NOT RECOMMEND FOR: Extremely wide gaps or parts with limited access to joints, parts and
tooling with limited access
COMPLEXITY: High; Additional advanced user training required
COST: High

3D Camera
Yaskawa utilizes a Canon 3D imaging solution for complex bin picking automation. This is not a
typical sensor for applications merely welding the same part and orientation. This solution
enables the use of a material handling robot to pick up a part, place it into tooling, weld using a
welding robot, and then remove the part for a completely automated process. With this type of
technology, all factors of complexity and cost increase from the other solutions.
BEST FOR: Randomly placed parts and “lights out” automation when placing them in a fixture
NOT RECOMMEND FOR: Simpler jobs that can be conquered more economically
COMPLEXITY: Very High; Additional advanced user training required
COST: Very High

When do Sensors Make Sense?

Sensor technology has come a long way in the recent past, providing game-changing
advantages for end users spanning diverse industries. From industrial welding robots to human-
collaborative robots (cobots), sensor technology improvements are helping companies handle
the diversity of applications required, especially where robotic welding is concerned. Even 3D
scanning and modeling sensors that have been developed for inspection are being researched
for one-off weld automated programming to open yet another generation of innovative solutions.
So, when do sensors make sense? If one has a redundant part with variations that tooling and
part consistency, or design, cannot resolve, there will be a sensor that can. Keeping that in
mind, expectations for ROI should be set with clear-cut goals associated with the investment
(reduced waste, improved quality, less down time, improved production, etc). While the initial
cost of robotic implementation may seem overwhelming to some manufacturers, understanding
the cost savings associated with a long-term approach to automation – and subsequent
technologies, like sensors – is essential.
Return on investment is usually realized quickly aside from sticker shock and should be
discussed in more detail with an automation integrator. Moreover, education about the different
types of sensors (and their capabilities) available for advanced robotic welding solutions will
make it easier for manufacturers to tackle the most difficult, dangerous and dirty tasks, leading
to higher production, better quality, and ultimately increased profitability.
1 Robotic arc welding sensors and programming in industrial applications, International Journal
of Mechanical and Materials Engineering, December 2015
2 Robot Sensor Market Outlook – Industry Size, Share Report 2018-2024, Global Market
Insights, 2018
3 Robot Sensor Market Outlook – Industry Size, Share Report 2018-2024, Global Market
Insights, 2018

With the kind permission of Josh Leath

What are the models in the Blue series?

SkyBlue
SkyBlue is our standard laser scanner. It can be used during welding and provide measurements for
Tracking Point and other geometric parameters usable in adaptive welding.

LightBlue
LightBlue is a laser scanner operating for positioning and pre-scanning of workpieces. LightBlue is not
operating during active welding.

SmartBlue
SmartBlue is the inspection camera of the Blue series. On top of laser scanner, it supports ultrasonic
transducers to support internal inspection of the workpiece cracks and problems inside the weld. It can
be used during active welding. By positioning SmartBlue on the backside of the welding torch one can
scan for quality in the same pass after welding.

DeepBlue
DeepBlue operates underwater in saline water and can be used for quality inspection of Ship Bottoms,
Naval constructions, Ship Propeller quality status. If underwater welding robot is used it can guide the
robot in a similar way like extra water path correction.

WideBlue
WideBlue operate at high distances of 1000 mm, 1500 mm or 2000 mm from the front of the camera.

OfflineBlue
Offline Simulator

6DBlue
6DOF camera for general purpose applications.

Product Selection Matrix

 OfflienBlue
SmartBlue

WideBlue

DeepBlue
LightBlue
SkyBlue

6DBlue
Live Welding Applications Y N Y N Y N Y
Adaptive Weldiing Y N Y N Y N Y
Simulation Y Y Y Y Y Y Y
Scanning and Positioning Y Y Y Y Y N Y
Safe Education N N N N N Y N
Inspection and Quality control Partial Partial FULL Partial FULL N Y
Underwater operation N N N N Y N N
Reprocessing of scans Y Y Y Y Y Y Y
Measurement 2.5D 2.5D 2.5D 2.5D 2.5D 2.5D/6D 6D

What are the Viewing Ranges?

For all systems we have standard viewing ranges. Customized viewing ranges are possible as well.

Stand Off Far end viewing Depth of View Precision Application

Short range 20mm 75mm 55mm 0.01mm Precise fine
objects
Standard 110mm 230mm 120mm 0.05mm Regular
Range workpieces
of different
kind
Far Range 150mm 300mm 150mm 0.1mm Big
workpieces
Wide Blue 500mm 1500mm 1000mm 1mm Far range
Range positioning.